Condenser Cooler Cleaning in the Plastics Industry

Condensers are essential components in the plastics manufacturing, blow molding and recycling industries as they play a crucial role in the production and processing of plastic products.

• Blow Molding: Condensers used in the production of blown moulded products are designed to catch and remove the volatile vapours released in the heating of plastics in the extrusion stage. Over time this sticky “wax” builds up reducing the effectiveness of the “cooler”.
• Plastics Manufacturing: In the plastics manufacturing process, condensers are used to cool and condense hot gases and vapours into a liquid state. The condenser removes the heat from the process and converts the vapor back into a liquid, which can then be reused or disposed of. The condenser is an important component in the production process as it helps maintain the quality of the final product by removing impurities and ensuring the production process runs efficiently.
• Recycling: Condensers are used in the plastic industry as part of the process of extrusion, when heating plastic hot gases and vapours are produced, which need to be cooled and condensed into a liquid state before they can be safely reused or disposed of. This is where condensers come into play.

Why do condensers need cleaning?

Condensers need cleaning to maintain their performance and efficiency. However, condensers often become contaminated with various substances that can negatively impact the quality of the final product. Over time, contaminants such as residual plastics, oils, and chemicals used in the production process can accumulate on the surface of the condenser, causing clogging, corrosion, and reduced heat transfer.

By removing these contaminants through cleaning, the performance of the condenser is restored, ensuring the production process runs smoothly and the final product meets the desired quality standards. Regular cleaning can help to prevent the reaccumulation of contaminants and prolong the life of the condenser, reducing the need for costly repairs or replacement.

How do you clean condensers?

To ensure the optimal performance of condensers, it is essential to implement a cleaning regimen that removes the contaminants and prevents their reaccumulation.

• Ultrasonic cleaning: Uses high-frequency sound waves to agitate and remove contaminants from the surface of the condenser. This method is particularly effective for removing residual plastics and oils that have accumulated on the surface. The sound waves create high-energy cavitation bubbles that implode and remove the contaminants from the surface.
• Chemical cleaning: This method involves the use of chemical solutions to dissolve and remove contaminants from the surface of the condenser. This method is effective for removing oils and greases and is typically performed in a controlled environment.
• Mechanical cleaning: This method involves using tools such as brushes, scrapers, and high-pressure water to physically remove contaminants from the surface of the condenser. This method is often used in combination with other cleaning methods, such as chemical cleaning, to achieve the best results.
• Jet washing: Jet washing can be effective at cleaning condensers but the fragile aluminium fins that surround the tubes can be very easily damaged with such high pressures. Its good practice to jet from further away at a high temperature to prevent “folding”.

Each of these cleaning methods has its own advantages and disadvantages, and the best method will depend on the type of contaminants present, the size and complexity of the condenser, and the resources available. In some cases, a combination of methods may be used to achieve the best results.

Take a look at some of the results we can achieve:

The benefits of cleaning condensers

Cleaning condensers is essential to maintaining the performance and efficiency of the plastics manufacturing and recycling industries. By removing contaminants and preventing their reaccumulation, businesses can ensure the production process runs smoothly, and the final product meets the desired quality standards. In addition to preventing equipment breakdown, downtime and saving companies from unexpected costs!

It is the use of a variety of cleaning processes to achieve the desired level of cleanliness that differentiates Sonic Solutions from both in-house cleaning and other subcontract cleaning operations. This cleaning expertise and experience combined with our flexibility and desire to deliver what the customer wants, when they want it, explains why some of the biggest and most demanding plastics manufacturers like Clean Tech and Alpla rely on us to get rid of their unwanted contaminants from working parts.